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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DEVELOPMENT OF DATABASE FOR CHECKING FIXTURES
FOR AUTOMOTIVE PARTS
This report submitted in accordance with requirement of Universiti Teknikal Malaysia
Melaka (UTeM) for Bachelor Degree of Manufacturing Engineering
(Manufacturing Design) (Hons.)
by
SHAHRUL IMRAN BIN ZULKIFLI
B051010136
880302-26-5441
FACULTY OF MANUFACTURING ENGINEERING
2014
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Development of Database for Checking Fixtures for Automotive Parts
SESI PENGAJIAN: 2013/14 Semester 2 Saya SHAHRUL IMRAN BIN ZULKIFLI mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan ( )
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap:
2934-H Taman Muhibbah
Jalan Sultanah Bahiyah
05350 Alor Setar, Kedah
Tarikh: ________________________
Disahkan oleh:
Cop Rasmi: Tarikh: _______________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
FAKULTI KEJURUTERAAN PEMBUATAN
Tel : +606 331 6019 | Faks : +606 331 6431/6411
Rujukan Kami (Our Ref) : Rujukan Tuan (Your Ref) :
23 Jun 2014
Pustakawan Perpustakaan UTeM Universiti Teknikal Malaysia Melaka Hang Tuah Jaya, 76100 Durian Tunggal, Melaka. Tuan/Puan, PENGKELASAN LAPORAN PSM SEBAGAI SULIT/TERHAD LAPORAN PROJEK SARJANA MUDA KEJURUTERAAN PEMBUATAN (MANUFACTURING DESIGN): SHAHRUL IMRAN BIN ZULKIFLI Sukacita dimaklumkan bahawa Laporan PSM yang tersebut di atas bertajuk “Development of Database for Checking Fixtures for Automotive Parts” mohon dikelaskan sebagai *SULIT / TERHAD untuk tempoh LIMA (5) tahun dari tarikh surat ini. 2. Hal ini adalah kerana IANYA MERUPAKAN PROJEK YANG DITAJA OLEH SYARIKAT LUAR DAN HASIL KAJIANNYA ADALAH SULIT. Sekian dimaklumkan. Terima kasih. Yang benar, ________________ * Potong yang tidak berkenaan
NOTA: BORANG INI HANYA DIISI JIKA DIKLASIFIKASIKAN SEBAGAI SULIT DAN
TERHAD. JIKA LAPORAN DIKELASKAN SEBAGAI TIDAK TERHAD, MAKA
BORANG INI TIDAK PERLU DISERTAKAN DALAM LAPORAN PSM.
DECLARATION
I hereby, declared this report entitled “Development of Database for Checking Fixtures
for Automotive Parts” is the results of my own research except as cited in references.
Signature : ………………………………………
Author’s Name : SHAHRUL IMRAN BIN ZULKIFLI
Date : ………………………………………
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirement for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Design) (Hons.). The member of the supervisory committee
is as follow:
………………………………………..
(ZULKEFLEE BIN ABDULLAH)
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ABSTRAK
Tujuan kajian ini adalah untuk membangunkan pangkalan data untuk Semakan Jadual
untuk Bahagian Automotif. Bahagian-bahagian yang digunakan dalam proses semakan
seperti “clamper”, “stand” dan “toggle”. Matlamat projek ini adalah untuk melaksanakan
pangkalan data memeriksa lekapan bahagian. Projek bermula ialah mengenal pasti
masalah semasa yang dihadapi oleh pereka bentuk di jabatan reka bentuk. Masa
terbuang telah menjadi masalah utama yang telah pereka untuk dihadapi. Semua data
dan maklumat yang berkaitan dengan projek ini telah dicari dan direkodkan dalam
kajian literatur. Perisian Catia digunakan sebagai perisian CAD untuk membina model
tiga dimensi untuk reka bentuk bahagian-bahagian semua bahagian di perpustakaan
bahagian-bahagian yang. Semua bahagian-bahagian yang dianjurkan dalam tiga saiz
yang berbeza yang ditentukan oleh saiz panel badan kereta. Merujuk kepada keputusan
itu, perpustakaan baru terbentuk atau dibangunkan dengan menggunakan perisian Catia
untuk membantu pereka dalam proses reka bentuk lekapan pemeriksaan. Pengesahan
perpustakaan telah dijalankan dengan syarikat itu untuk menguji keberkesanan,
kebolehgunaan dan kesesuaian. Oleh itu, dengan alat ini dan kaedah telah
mempercepatkan lekapan proses reka bentuk memeriksa untuk menjadi lebih cepat dan
cekap.
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ABSTRACT
The purpose of this study is to develop database for Checking Fixtures for Automotive
Parts. The parts that used in the checking fixture process such as clamper, stand and
toggle. The goal of this project is to implement a database of checking fixtures parts.
The project started is identify the current problem that faced by the designer at design
department. Idle time has been the major problem that designer have to faced. All the
data and information related to this project has been sought and recorded in the literature
review. Catia software is used as CAD software to construct three-dimensional models
for the design of the parts all the parts in the parts library. All the parts are organized in
three different sizes which are determined by the size of car body panel. Referring to the
result, new libraries are formed or develop using the Catia software to aid the designers
in the checking fixture design process. The validation of the library has been conducted
with the company to test the effectiveness, usability and relevancy. Therefore, with this
tool and method have accelerate the checking fixtures design process to become more
quickly and efficient.
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DEDICATION
To my beloved family, my respectful supervisor and examiner, my fellow friends and all
the parties involved, thank you so much.
iv
ACKNOWLEDGEMNET
First and foremost, gratefully wishes to the Almighty, ALLAH S.W.T for all His
blessing.
This opportunity has been taken to express sincere appreciation and gratitude to
respective supervisor, Mr. Zulkeflee bin Abdullah, for constructive guidance, consistent
encouragement, and fulfilling aspiration in completing this project. Also for my
supervisor at Shazu Engineering Sdn.Bhd for her kindness, patients, and supporting, I
wish her thanks a lot.
Also this chance has been taken to wish thank to the entire workers at the Shazu
Engineering for took valuable time to teach and give a proper tutoring to understand
about the checking fixtures and teach something that very useful in manufacturing
design.
This opportunity absolutely taken to wish special thanks for several people especially all
the family members for supporting physically and spiritually throughout in completing
this project. Finally, thank wishes to all friends that give me a support and for a sharing
an idea during the completion this final year report.
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TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Table viii
List of Figure x
List of Abbreviations and Acronyms xiv
CHAPTER 1 1
1.1 Background of the Study 1
1.2 Problem Statement 3
1.3 Objective of the Study 4
1.4 Scope of the Research 4
1.5 Potential Benefits from the Research 5
1.5.1 Benefits to Industry 5
1.5.2 Benefits to University 5
CHAPTER 2 6
2.1 Jigs and Fixture 6
2.2 Fixture Design 9
vi
2.2.1 The fixture Design 9
2.2.2 Part Prints 10
2.2.3 Fixture Drawing 11
2.2.4 Frame/Base 12
2.2.5 Locator 13
2.2.6 Clamps 14
2.2.7 Bushings 19
2.2.8 Brackets 20
2.2.9 Fastener 21
2.3 Automotive Body in White 22
2.4 Checking Fixture 24
2.4.1 Stationary Checking Fixtures 25
2.5 Definition of Design 26
2.6 Design Research 27
2.7 Industrial Design 28
2.8 Development Lead Time 29
2.9 Productivity in Automotive 31
CHAPTER 3 33
3.1 Plan and Activities 33
3.2 Design of Research 35
3.3 Background of the Research Location 35
3.4 Research Methodology 36
3.5 Framework of the Research 37
vii
3.5.1 Problems Identification 39
3.5.2 Design Concept 42
3.5.3 Size of Checking Fixtures 45
3.5.4 Determine Standard Parts of Checking Fixtures 47
3.5.5 Design the Parts using CAD 48
3.5.6 Organize the Drawing File 49
CHAPTER 4 51
4.1 Introduction 51
4.2 Checking Fixtures Design Loose Panel Parts 51
4.2.1 Body Parts (Panel Data) 53
4.3 Checking Fixture Library 87
4.3.1 Workflow Used of the Library Part 88
4.4 Checking Fixture Database Library Validation 97
4.4.1 Validation Method 97
4.4.2 Validation Result 100
CHAPTER 5 101
5.1 Conclusion 101
5.2 Recommendation for Future Work 102
REFERENCES
APPENDIX
viii
LIST OF TABLE
Table 3.1: Interview Questions 37
Table 4.1: Size of Checking Fixture 54
Table 4.2: Type of Clamp Used 59
Table 4.3: Types of Clamps 60
Table 4.4: L-bracket Size 63
Table 4.5: Dowel Pin 67
Table 4.6: Diamond Pin 67
Table 4.7: Marking Pin 70
Table 4.8: Small Round Pin 73
Table 4.9: Medium Round Pin 74
Table 4.10: Large Round Pin 74
Table 4.11: Small Hinge Pin 75
Table 4.12: Medium Hinge Pin 75
Table 4.13: Large Hinge Pin 76
Table 4.14: Small Bush Diamond 76
Table 4.15: Medium Bush Diamond 77
Table 4.16: Large Bush Diamond 77
ix
Table 4.17: Small Bush Round and Marking 77
Table 4.18: Medium Bush Round and Marking 78
Table 4.19: Large Bush Round and Marking 78
Table 4.20: Pin Clip and Holder Pin 79
Table 4.21: Caster Wheel Sizes 80
Table 4.22: Types of Cover Riser/Datum 81
Table 4.23: Types of Bolt 82
Table 4.24: Types of Bolt 83
Table 4.25: Types of Knob Lobed 83
Table 4.26: Types of Lifting Eye Bolt 84
Table 4.27: Types of Screw 84
Table 4.28: Type of Name Plate 86
Table 4.28: Design Process Brief (First Trial) 98
Table 4.29: Design Process Brief (Second Trial) 99
x
LIST OF FIGURES
Figure 2.1: Fixture Design 9
Figure 2.2: Fixture Drawing 11
Figure 2.3: Base of CF 12
Figure 2.4: Locator 13
Figure 2.5: Clamps 14
Figure 2.6: Horizontal-handle toggle clamps 15
Figure 2.7: Clamped Position 15
Figure 2.8: Vertical Handle Toggle Clamps 16
Figure 2.9: Clamped Position 16
Figure 2.10: Type of Bushing 17
Figure 2.11: Brackets angle 20
Figure 2.12: Example of fastener 21
Figure 2.13: Body in White 22
Figure 2.14: Structural part of BIW 23
Figure 2.15: Checking Fixtures 24
Figure 2.16: Definitions of Major Development Phases 29
Figure 3.1: Methodology Flowchart 34
xi
Figure 3.2: Checking Fixture Process 35
Figure 3.3: Framework of Research 38
Figure 3.4: Flow Chart of Approval Checking Fixture Process 40
Figure 3.5: Categories of Idle Time. 41
Figure 3.6: Design Concept 42
Figure 3.7: Example of Panel Setting. 44
Figure 3.8: Example of Small Checking Fixtures 46
Figure 3.9: Example of Medium Checking Fixtures. 46
Figure 3.10: Example of Large Checking Fixtures. 46
Figure 4.1: CF Main Elements 52
Figure 4.2: Front Area of Car Parts 53
Figure 4.3: Example of basic body parts of the car 54
Figure 4.4: Bracket Hvac Unit Lower Panel (Small) 55
Figure 4.5: Rail Roof Panel (Large) 55
Figure 4.6: Front Floor Panel (Large) 55
Figure 4.7: Front Floor Panel (Large) 56
Figure 4.8: Cowl Top Inner Panel (Medium) 56
Figure 4.9: Cowl Top Outer Panel (Medium) 56
Figure 4.10: Small Base Structure 57
Figure 4.11: Medium Base Structure 58
xii
Figure 4.12: Large Base Structure 59
Figure 4.13: Clamper Stand with Toggle Clamps 64
Figure 4.14: Type C 65
Figure 4.15: Type D 65
Figure 4.16: Type E 65
Figure 4.17: Type A 66
Figure 4.18: Type B 66
Figure 4.19: Caster Wheel Types 80
Figure 4.20: CF Part Library Structures 87
Figure 4.21: Step 1 89
Figure 4.22: Step 2 89
Figure 4.23: Step 3 90
Figure 4.24: Step 4 90
Figure 4.25: Step 5 91
Figure 4.26: Step 6 91
Figure 4.27: Step 7 92
Figure 4.28: Clamper Stand with Toggle 92
Figure 4.29: Step 8 93
Figure 4.30: Pin and Bush 93
Figure 4.31: Step 9 94
Figure 4.32: Assembly of L-bracket 94
xiii
Figure 4.33: Step 10 95
Figure 4.44: Complete Checking Fixture Design 95
xiv
USED ACRONYMS / ABBREVIATIONS
CF - Checking Fixture
BIW - Body in White
PQR - Part Quality Requirement
SESB - Shazu Engineering Sdn. Bhd.
1
CHAPTER 1
INTRODUCTION
Chapter one describes the overall background of this project research. The scope of this
research is focused at Shazu Engineering Sdn. Bhd. The content of this chapter includes
background, problem statement, project objectives, scope of project, and potential
benefits from the project.
1.1 Background of the Study
This study introduces development of a library or catalogue for Checking Fixtures items
like clamper, stand, and toggle to be used in Checking Fixtures process. Shazu
Engineering Sdn.Bhd. has been involved in the automotive industry since its
establishment in September 2003. The company is owned by 100% Bumiputra and is
entrusted to provide the most cost effective, reliable and accurate consultation services
to the customers. As of mid-2009, Shazu Engineering has been assigned as quality
consultant for the development of Savvy, Satria Neo, Persona, New Saga and Exora.
Starting with only four employees, currently Shazu is supported by 27 dedicated
employees with high technical expertise and management skills.
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Established in the year 2003, Shazu Engineering has been an eminent
manufacture of Checking Fixtures & Assembly fixture for many companies. Shazu
Engineering is engaged in manufacturing custom designed as well as standard
specification products. Shazu Engineering qualified workforce is able to ensure
complete compliance with their clients’ requirements and specifications.
The fixtures are manufactured from high quality raw material procured from
local vendors with extremely reliable reputations to produce high grade Checking
Fixtures and Assembly Fixtures.
Auto-body parts include the stamping parts, subassemblies jointed with stamping
parts, the auto-body framework and all kind of trims which are formed into complicated
surfaces. The quality of covering these parts considerably affects car performance and
airproofing. During the manufacturing process, in order to ensure parts quality, it is
important to measure parts with checking fixtures which are used to locate and hold the
workpiece in 3D space according to measure planning.
Checking fixtures for auto body parts have different types according to
measuring planning and parts features. The main type of such checking fixtures can be
described as follows; measuring fixtures, combined checking fixtures, profile modeling
casting checking fixtures, and additional checking fixtures. Correctly selecting the
checking fixture type for auto body parts is a first step to design a good checking fixture.
In the quality control process of auto-body manufacturing, selecting which type
of checking fixture takes into consideration on the features and parameters of the part
that would be measured; so the information of the auto body part is important for
checking fixtures is not unique since numerous plans are possible. Traditionally, the
selection of a checking fixtures type relies heavily on the designer’s expertise and
experience. Performance evaluation of a checking fixtures type is also very difficult due
to high non-linear relationship of the design parameters. Consequently, it is not
immediately apparent if a checking fixture type is optimal or near optimal for the given
part.
3
1.2 Problem Statement
As products and processes are becoming more complex, the decision making involved
in product design and manufacturing engineering have to consider many variables.
Time Loss is some of the major problem experienced in SESB. By reducing time loss,
the production output and profitability to the company will increase besides reduce the
cost such as salary for overtime work. Design department preparing the concept based
on quality integration mode. From the concept, designer will plan the design checking
fixtures based on the customer requirements. Designer needs to design the checking
fixtures based on the concept, so it will take time to make it, so as a designer, time
consuming and accuracy is very important. When it takes too long time and will cause
work to be inefficient. It is important to accurately design a checking fixture. It can be
time consuming to change the design if the design is not accurate or design changed by
the customers. Checking fixtures has many types of size. It depends on the customers
which part of the car that they want to develop such as rear floor, front floor, side door,
panel roof and many mores. Checking fixtures have many child parts such as toggle
clamp, clamper, and stand. It will take time to design all the parts to make a checking
fixtures process done.
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1.3 Objective of the Study
The purpose of this study is to develop database for (CF) Checking Fixtures for
automotive parts. The complexity and detail of a database design is dictated by the
complexity and size of the checking fixtures itself. Overall, the study objective involves
three main stages which are:
i. To identify the problem of time constraints in the design process of Checking
Fixtures.
ii. To recommend tools and methods used in Checking Fixture process.
iii. To develop a library or catalogue for Checking Fixtures processes parts.
1.4 Scope of the Research
This study seeks to solve the problems as SESB located at Shah Alam, Selangor. SESB
is a company that manufactures checking fixtures for cars and listed among the
automotive industry. This study will focus primarily on the loose panel part and time
loss at the design department. Interview and observation methods also include gaining
more understanding about some detail processes. The result of the study will then be
used to achieve the objectives. This study was limited only for Shazu Engineering Sdn.
Bhd.
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1.5 Potential Benefits from the Research
Following are the potential benefits that can be obtained from the carried out
project. The potential benefits from the project had been classified into two categories:
1.5.1 Benefits to Industry
The benefits of the conducted project to the industry can be summaries as below:
a) The manufacturing industry and students can exchange knowledge
between each other.
b) Increase the accuracy of designing the important automotive parts.
c) The improvements of the work efficiency.
1.5.2 Benefits to University
The benefits of the conducted project to the industry can be summaries as
follow:
a) Create the relationship between UTeM and manufacturing industry.
b) Providing possible subject to be taught in UTeM that is applicable in real
industry world.
c) The mission of UTeM achieved, which is to develop a curriculum that
encourages critical thinking, problem solving, teamwork and social skills.